GA24 Handbook Variable-area flowmeter KROHNE
: IMPRINT :::::::::::::::::::::::::::::::::: All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without the prior written authorisation of KROHNE Messtechnik GmbH. Subject to change without notice. Copyright 2011 by KROHNE Messtechnik GmbH - Ludwig-Krohne-Str. 5-47058 Duisburg (Germany) 2
CONTENTS 1 Safety instructions 5 1.1 Intended use... 5 1.2 Certifications... 5 1.3 Safety instructions from the manufacturer... 6 1.3.1 Copyright and data protection... 6 1.3.2 Disclaimer... 6 1.3.3 Product liability and warranty... 7 1.3.4 Information concerning the documentation... 7 1.3.5 Warnings and symbols used... 8 1.4 Safety instructions for the operator... 8 2 Device description 9 2.1 Scope of delivery... 9 2.2 Nameplate... 10 2.3 Description code... 10 3 Installation 11 3.1 Notes on installation...11 3.2 Storage... 11 3.3 Installation condtitions...11 3.4 Transport locks... 11 4 Electrical connections 12 4.1 Safety instructions... 12 4.2 Limit switches GA24... 12 4.2.1 MS14 limit switch connection... 13 4.2.2 TG21 limit switch connection... 13 4.3 Limit switch settings...14 4.3.1 Limit switch settings MS14... 14 4.3.2 Limit switch settings TG21... 14 4.4 Limit switch function reversal... 15 4.4.1 Limit switch function reversal MS14... 15 4.4.2 Limit switch function reversal TG21... 15 5 Service 16 5.1 Maintenance... 16 5.2 Spare parts availability...16 5.3 Availability of services... 16 5.4 Returning the device to the manufacturer... 17 5.4.1 General information... 17 5.4.2 Form (for copying) to accompany a returned device... 18 5.5 Disposal... 18 3
CONTENTS GA24 6 Technical data 19 6.1 Operating principle... 19 6.2 Technical data... 20 6.3 Dimensions and weights... 23 6.4 Measuring ranges...24 7 Notes 26 4
SAFETY INSTRUCTIONS 1 1.1 Intended use The variable area flowmeters are suitable for measuring gases and liquids. The devices are particularly suitable for the measurement of: Liquids Hydrocarbons Water Chemicals with low corrosiveness Industrial gases DANGER! For devices used in hazardous areas, additional safety notes apply; please refer to the Ex documentation. WARNING! Responsibility for the use of the measurement devices with regard to suitability, intended use and corrosion resistance of the used materials against the measured fluid lies solely with the operator. The manufacturer is not liable for any damage resulting from improper use or use for other than the intended purpose. Do not use any abrasive or highly viscous media. 1.2 Certifications The device fulfils the statutory requirements of the following EC directives: Pressure Equipment Directive 97/23/EC Devices with contacts: EMC Directive 2004/108/EC Devices for use in hazardous areas: ATEX Directive 94/9/EC The manufacturer certifies successful testing of the product by applying the CE marking. 5
1 SAFETY INSTRUCTIONS GA24 1.3 Safety instructions from the manufacturer 1.3.1 Copyright and data protection 1.3.2 Disclaimer The contents of this document have been created with great care. Nevertheless, we provide no guarantee that the contents are correct, complete or up-to-date. The contents and works in this document are subject to copyright. Contributions from third parties are identified as such. Reproduction, processing, dissemination and any type of use beyond what is permitted under copyright requires written authorisation from the respective author and/or the manufacturer. The manufacturer tries always to observe the copyrights of others, and to draw on works created in-house or works in the public domain. The collection of personal data (such as names, street addresses or e-mail addresses) in the manufacturer's documents is always on a voluntary basis whenever possible. Whenever feasible, it is always possible to make use of the offerings and services without providing any personal data. We draw your attention to the fact that data transmission over the Internet (e.g. when communicating by e-mail) may involve gaps in security. It is not possible to protect such data completely against access by third parties. We hereby expressly prohibit the use of the contact data published as part of our duty to publish an imprint for the purpose of sending us any advertising or informational materials that we have not expressly requested. The manufacturer will not be liable for any damage of any kind by using its product, including, but not limited to direct, indirect or incidental and consequential damages. This disclaimer does not apply in case the manufacturer has acted on purpose or with gross negligence. In the event any applicable law does not allow such limitations on implied warranties or the exclusion of limitation of certain damages, you may, if such law applies to you, not be subject to some or all of the above disclaimer, exclusions or limitations. Any product purchased from the manufacturer is warranted in accordance with the relevant product documentation and our Terms and Conditions of Sale. The manufacturer reserves the right to alter the content of its documents, including this disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable in any way for possible consequences of such changes. 6
SAFETY INSTRUCTIONS 1 1.3.3 Product liability and warranty The operator shall bear responsibility for the suitability of the device for the specific purpose. The manufacturer accepts no liability for the consequences of misuse by the operator. Improper installation and operation of the devices (systems) will cause the warranty to be void. The respective "Standard Terms and Conditions" which form the basis for the sales contract shall also apply. 1.3.4 Information concerning the documentation To prevent any injury to the user or damage to the device it is essential that you read the information in this document and observe applicable national standards, safety requirements and accident prevention regulations. If this document is not in your native language and if you have any problems understanding the text, we advise you to contact your local office for assistance. The manufacturer can not accept responsibility for any damage or injury caused by misunderstanding of the information in this document. This document is provided to help you establish operating conditions, which will permit safe and efficient use of this device. Special considerations and precautions are also described in the document, which appear in the form of underneath icons. 7
1 SAFETY INSTRUCTIONS GA24 1.3.5 Warnings and symbols used Safety warnings are indicated by the following symbols. DANGER! This information refers to the immediate danger when working with electricity. DANGER! This warning refers to the immediate danger of burns caused by heat or hot surfaces. DANGER! This warning refers to the immediate danger when using this device in a hazardous atmosphere. DANGER! These warnings must be observed without fail. Even partial disregard of this warning can lead to serious health problems and even death. There is also the risk of seriously damaging the device or parts of the operator's plant. WARNING! Disregarding this safety warning, even if only in part, poses the risk of serious health problems. There is also the risk of damaging the device or parts of the operator's plant. CAUTION! Disregarding these instructions can result in damage to the device or to parts of the operator's plant. These instructions contain important information for the handling of the device. LEGAL NOTICE! This note contains information on statutory directives and standards. HANDLING This symbol designates all instructions for actions to be carried out by the operator in the specified sequence. i RESULT This symbol refers to all important consequences of the previous actions. 1.4 Safety instructions for the operator WARNING! In general, devices from the manufacturer may only be installed, commissioned, operated and maintained by properly trained and authorized personnel. This document is provided to help you establish operating conditions, which will permit safe and efficient use of this device. 8
DEVICE DESCRIPTION 2 2.1 Scope of delivery Inspect the cartons carefully for damage or signs of rough handling. Report damage to the carrier and to the local office of the manufacturer. Check the packing list to check if you received completely all that you ordered. Look at the device nameplate to ensure that the device is delivered according to your order. Check for the correct supply voltage printed on the nameplate. Figure 2-1: Scope of delivery 1 Measuring device in ordered version 2 Manual 3 Certificates, calibration report (supplied to order only) 9
2 DEVICE DESCRIPTION GA24 2.2 Nameplate Look at the device nameplate to ensure that the device is delivered according to your order. Check for the correct supply voltage printed on the nameplate. 1 Device type 2 Manufacturer 3 Internet site 4 Notified ATEX body 5 Note manual 6 Ex data 7 Serial Number 8 Year of manufacture 9 PED data 10 Sizing data: temperature & pressure Additional markings on the measuring device SO - sales order / item Tag-No - Measuring point identifier PA - KROHNE order AC - article code 2.3 Description code The description code* GA24 consists of the following elements: 1 Type series measuring unit GA24 2 Material of connection R - stainless steel PTFE - stainless steel with PTFE lining 3 Limit switch K1 - One limit switch K2 - Two limit switches * positions which are not needed are omitted (no blank positions) 10
INSTALLATION 3 3.1 Notes on installation Inspect the cartons carefully for damage or signs of rough handling. Report damage to the carrier and to the local office of the manufacturer. Check the packing list to check if you received completely all that you ordered. Look at the device nameplate to ensure that the device is delivered according to your order. Check for the correct supply voltage printed on the nameplate. 3.2 Storage Store the device in a dry and dust-free location. Avoid lasting direct exposure to the sun. Store the device in its original packing. The permissible storage temperature for standard devices is -40...+80 C / -40...+176 F. 3.3 Installation condtitions CAUTION! When installing the device in the piping, the following points must be observed: The variable area flowmeter must be installed vertically (measuring principle). Flow direction from bottom to top. For installation recommendations please refer also to VDI/VDE 3513 Sheet 3. Before connecting, blow or flush out the pipes leading to the device. Pipes for gas flow need to be dried before the device is installed. Use connectors suitable for the particular device version. Align the pipes centrically with the connection bores on the measuring device so they are free of stresses. If necessary, support the pipeline to reduce vibrations being transmitted to the measuring device. Do not lay signal cables directly next to cables for the power supply. 3.4 Transport locks A plastic rod is fitted to secure the float during transportation. This must be removed prior to starting up. Remove the protective cover on the top flange and the rod lock from the glass. 11
4 ELECTRICAL CONNECTIONS GA24 4.1 Safety instructions DANGER! All work on the electrical connections may only be carried out with the power disconnected. Take note of the voltage data on the nameplate! DANGER! Observe the national regulations for electrical installations! DANGER! For devices used in hazardous areas, additional safety notes apply; please refer to the Ex documentation. WARNING! Observe without fail the local occupational health and safety regulations. Any work done on the electrical components of the measuring device may only be carried out by properly trained specialists. Look at the device nameplate to ensure that the device is delivered according to your order. Check for the correct supply voltage printed on the nameplate. 4.2 Limit switches GA24 The flowmeters GA24 can be equipped with a maximum of two bistable limit switches. Bistable function: Stable switching when passing through the switching point Use, selection and function - see Technical Data Figure 4-1: Types of limit switch 1 MS 14/I - floating, bistable reed contact 2 TG21 - bistable, with integrated switching lug and slotted proximity switch 12
ELECTRICAL CONNECTIONS 4 4.2.1 MS14 limit switch connection Figure 4-2: Connection limit switch type MS14 1 Connection Reed-switch 2 Connection Receiver device 3 Terminal connection (potential-free) The switching function requires a float with integrated magnet. 4.2.2 TG21 limit switch connection Figure 4-3: Connection limit switch type TG21 1 Terminal - 2 Terminal + The TG 21 is adapted for switch amplifiers with an intrinsically safe circuit as per DIN EN 50227 NAMUR. The TG 21 includes an inductive slotted proximity switch with bistable switching characteristics. The slotted proximity switch is activated by the immersion of an aluminum lug. The magnet of the immersion lug is moved by the magnet in the float. The switching function requires a float with integrated magnet. 13
4 ELECTRICAL CONNECTIONS GA24 4.3 Limit switch settings 4.3.1 Limit switch settings MS14 Undo bracket screw 1 and set switching position Secure bracket screw 1 The distance between the limit switch and the casing is factory set with clamp screw 2 so that the limit switch touches the glass taper at the maximum switching point. The limit switch must be rotated 180 to reach the lower range of the scale. 4.3.2 Limit switch settings TG21 Undo bracket screw 1 and set switching position Secure bracket screw 1 The distance between the limit switch and the casing is factory set at approx. 1 mm (0.039") with the clamping screw 2. 14
ELECTRICAL CONNECTIONS 4 4.4 Limit switch function reversal 4.4.1 Limit switch function reversal MS14 The contact function can be changed by reconnecting the reed cartridge screwed into the cartridge housing: Closing as flow increases:arrow on reed cartridge points towards measuring glass. Closing as flow decreases:arrow on reed cartridge points away from measuring glass. 4.4.2 Limit switch function reversal TG21 The contact function can be changed from normally open to normally closed by moving the position of the slotted proximity switch 3. 1 Magnet 2 Contact vane 3 Slot sensor 4 Counter-magnet 5 Grub screw 6 Detaching screw slot sensor Once the screw 6 has been undone, the slotted proximity switch 3 can be moved to the other end position. If there is the possibility of vibrations triggering an improper switching operation, the strength of the force closure between the adjustment magnet and counter magnet 4 can be adjusted on the immersion lug 2 using the grub screw 5. The switching reproducibility is < 3% of the final measuring range value and is affected by the strength of the force closure. 15
5 SERVICE GA24 5.1 Maintenance The flowmeter should be checked for signs of dirt, corrosion, mechanical wear and damage to the measuring glass during routine maintenance of the system and pipelines. We advise that inspections be carried out at least once per year. CAUTION! Pressurized pipes have to be depressurized before removing the device. Empty pipes as completely as possible. In the case of devices used for measuring aggressive or hazardous media, appropriate safety precautions must be taken with regard to residual liquids in the measuring unit. Only the connecting couplings of the pipeline may be undone. Always use new seals when fitting the measuring device in the pipe. Avoid electrostatic charges when cleaning the surfaces (e.g. sight window)! Test the leak tightness using suitable means prior to starting up the measuring device again. 5.2 Spare parts availability The manufacturer adheres to the basic principle that functionally adequate spare parts for each device or each important accessory part will be kept available for a period of 3 years after delivery of the last production run for the device. This regulation only applies to spare parts which are subject to wear and tear under normal operating conditions. 5.3 Availability of services The manufacturer offers a range of services to support the customer after expiration of the warranty. These include repair, maintenance, technical support and training. For more precise information, please contact your local representative. 16
SERVICE 5 5.4 Returning the device to the manufacturer 5.4.1 General information This device has been carefully manufactured and tested. If installed and operated in accordance with these operating instructions, it will rarely present any problems. CAUTION! Should you nevertheless need to return a device for inspection or repair, please pay strict attention to the following points: Due to statutory regulations on environmental protection and safeguarding the health and safety of our personnel, manufacturer may only handle, test and repair returned devices that have been in contact with products without risk to personnel and environment. This means that the manufacturer can only service this device if it is accompanied by the following certificate (see next section) confirming that the device is safe to handle. CAUTION! If the device has been operated with toxic, caustic, flammable or water-endangering products, you are kindly requested: to check and ensure, if necessary by rinsing or neutralizing, that all cavities are free from such dangerous substances, to enclose a certificate with the device confirming that is safe to handle and stating the product used. 17
5 SERVICE GA24 5.4.2 Form (for copying) to accompany a returned device Company: Address: Department: Name: Tel. no.: Fax no.: Manufacturer's order no. or serial no.: The device has been operated with the following medium: This medium is: water-hazardous toxic caustic flammable We checked that all cavities in the device are free from such substances. We have flushed out and neutralized all cavities in the device. We hereby confirm that there is no risk to persons or the environment through any residual media contained in the device when it is returned. Date: Signature: Stamp: 5.5 Disposal CAUTION! Disposal must be carried out in accordance with legislation applicable in your country. 18
TECHNICAL DATA 6 6.1 Operating principle The flowmeter operates on the float measuring principle The measuring unit consists of a glass cone in which a float can move freely up and down. The flow goes from bottom to top. The float changes position so that the lifting force acting on it F1 is in equilibrium with the form drag F2 and its weight F3: F3 = F1 + F2 The height of the float is read on the scale of the measuring glass and indicates the flow rate. The top edge of the float marks the reading line for flow values. 19
6 TECHNICAL DATA GA24 6.2 Technical data The following data is provided for general applications. If you require data that is more relevant to your specific application, please contact us or your local representative. Additional information (certificates, special tools, software,...) and complete product documentation can be downloaded free of charge from the website (Download Center). Measuring system Application range Flow measurement of liquids, gases and vapors Operating method / measuring principle Variable area measuring principle Measured value Primary measured value Float position Secondary measured value Operating and standard volumetric flow Measuring accuracy Directive VDI / VDE 3513, sheet 2 (q G =50%) Measuring accuracy 1.o% Operating conditions Temperature Max. operating temperature TS Pressure Max. permitted operating gauge pressure PS at TS = 100 C Test pressure PT DN15, DN25 10 bar 1 DN40 9 bar 1 DN50 7 bar 1-40...+120 C / -40...+248 F Pressure equipment directive 97/23/EC Pressure equipment directive 97/23/EC or AD 2000-HP30 Installation conditions Inlet condition, run Outlet condition, run 1 other pressures upon request 5 x DN 3 x DN 20
TECHNICAL DATA 6 Materials Flange connection GA24/R Stainless steel 1.4404 (316 L) Flange connection GA24/PTFE Housing Measuring cone Suspended solid particle Suspended solid particle and insert Seals Stainless steel 1.14404 (316 L) with a liner made of PTFE Steel plate housing (zinc-plated with epoxy/polyester coating) Borosilicate glass Stainless steel 1.4571 (316 Ti) or Hastelloy C2000 PTFE/insert or TFM (PTFE) Aluminum Polypropylen (PP) PVDF (conforms to FDA) Neoprene PTFE Scherring PTFE sleeve Temperatures DANGER! For devices to be used in hazardous areas, special temperature ranges apply. These can be found in the separate instructions. Max. measuring temperature T m -40...+120 C 1-40...+248 F Max. ambient temperature T amb. -20...+100 C -4...+212 F 1 higher temperatures on request Types of limit switches Type Switching function Connection Shape Note MS 14/A bistable 2-wire, floating Reed contact Float with magnet required TG 21 bistable 2-wire NAMUR Slotted proximity switch Float with magnet required 21
6 TECHNICAL DATA GA24 Limit switch use Size Cone no. Limit switch Size Cone no. Limit switch DN15 N 18.07 MS14/A DN25 N 21.09 MS14/A TG21 N 18.09 MS14/A N 21.13 MS14/A TG21 N 18.13 MS14/A N 21.18 MS14/A TG21 N 19.09 MS14/A N 21.25 MS14/A TG21 N 19.13 MS14/A DN40 N 41.09 MS14/A TG21 N 19.19 MS14/A N 41.13 MS14/A TG21 N 19.26 MS14/A N 41.19 MS14/A TG21 DN50 N 51.10 MS14/A TG21 N 51.15 MS14/A TG21 N 51.21 MS14/A TG21 Technical Data Limit Switches Technical data MS14 Contact type Switching reproducibility Contact rating max. turn-on voltage Normally open or normally closed, can be reconnected < 2% of full-scale range 12VA 30VDC Max. switching current 0,5A Ambient temperature -20...+85 C / -4...+185 F Protection category acc. to IEC 60529 / EN IP44 529 Technical data TG21 Rated voltage 8VDC Current consumption, active surface open 3mA Current consumption, active surface 1mA covered Ambient temperature -25...+100 C / -13...+212 F Protection category acc. to IEC 60529 / EN IP 67 (NEMA 6) 529 22
TECHNICAL DATA 6 6.3 Dimensions and weights Dimensions Nominal size a b c d DN Inch mm Inch mm Inch mm Inch mm Inch 15 1/2" 500 19.7 300 11.8 84 3.31 82 3.23 25 1" 500 19.7 300 11.8 105 4.13 102 4.02 40 1 1/2" 500 19.7 300 11.8 125 4.92 122 4.80 50 2" 500 19.7 300 11.8 165 6.50 147 5.74 Weights approx. kg approx. Ib DN15 6 13 DN25 10 22 DN40 13 29 DN50 18 40 Process connection Connection dimensions according to Connection Pressure class Flanged connections EN 1092 DN15, DN25 PN25 EN 1092 DN40 DN50 PN10 ASME B16.5 1/2"...2" Class 150 lb / RF ASME B16.5 1/2"...2" Class 300 lb / RF 23
6 TECHNICAL DATA GA24 6.4 Measuring ranges Measuring span 10 : 1 Flow values 100% Reference condition: Water 20 C / Air 20 C - 1.013 bar abs. Float materials: 1 Stainless Steel or Hastelloy - 2 PTFE - 3 TFM - 4 Aluminium - 5 Polypropylen (PP) Materials 1 2 3 1 3 4 5 1 2 3 4 5 Cone Flow water [l/h] Flow air [m 3 /h] Max. pressure loss [mbar] N 18.07 DN15 40 25 13 1.5 0.6 0.8 0.5 9 6 2 3 1 N 18.09 63 40 22 2.2 0.95 1.2 0.7 9 7 3 3 2 N 18.13 100 63 35 3 1.5 1.8 1.2 9 8 3 4 2 N 19.09 160 100 55 5 2.2 2.8 1.8 13 9 4 5 2 N 19.13 250 160 85 8 3.3 4.5 2.8 16 11 4 5 2 N 19.19 400 250 140 - - - - 21 14 5 - - N 19.26 630 400 230 - - - - 27 17 6 - - N 21.09 DN25 630 400 230 18 1 9 11 7 22 14 6 8 3 N 21.13 1000 630 350 28 1 14 18 12 23 17 6 8 4 N 21.18 1600 1000 600 49 1-28 1 17 1 26 25 7 10 6 N 21.25 2500 1600 950 70 1-42 1 26 1 33 40 8 12 9 N 41.09 DN40 1600 1000 600 45 1 22 28 18 32 18 9 11 5 N 41.13 2500 1600 900 70 1 36 45 1 28 1 34 20 10 12 5 N 41.19 4000 2500 1500 128 1-76 1 46 1 38 24 11 15 8 N 51.10 DN50 4000 2500 1500 120 1 56 70 45 43 25 12 15 7 N 51.15 6300 4000 2400 190 1 90 110 1 70 1 47 30 13 16 7 N 51.21 10000 6300 3500 310 1-170 1 118 1 55 42 14 20 10 1 only possible with guided float The operating pressure should be at least double the pressure loss for liquids and five times for gases. The indicated pressure losses are valid for water and air at maximum flow rate. Conversion to other products or operating data is performed by KROHNE using the calculation method stipulated by VDI/VDE Directive 3513. 24
TECHNICAL DATA 6 Measuring span 10 : 1 Flow values 100% Reference condition: Water 68 F / Air 68 F - 14.7 psi Float materials: 1 Stainless Steel or Hastelloy - 2 PTFE - 3 TFM - 4 Aluminium - 5 Polypropylen (PP) Materials 1 2 3 1 3 4 5 1 2 3 4 5 Cone Flow, water [gph] Flow, air [scfm] Max. pressure loss [psi] N 18.07 DN15 10.6 6.6 3.43 0.93 0.37 0.5 0.31 0.1 0.1 0.03 0.04 0.02 N 18.09 16.6 10.6 5.81 1.36 0.59 1.2 0.43 0.1 0.1 0.04 0.04 0.03 N 18.13 26.4 16.6 9.25 1.86 0.93 0.74 0.74 0.1 0.1 0.04 0.06 0.03 N 19.09 42.3 26.4 14.5 3.1 1.36 1.7 1.1 0.19 0.13 0.06 0.07 0.03 N 19.13 66.0 42.3 22.5 4.96 2.05 2.8 1.7 0.2 0.16 0.06 0.07 0.03 N 19.19 105 66.0 37 - - - - 0.3 0.2 0.07 - - N 19.26 166 106 60.8 - - - - 0.4 0.25 0.09 - - N 21.09 DN25 166 106 60.8 11.2 1 5.58 6.8 4.3 0.3 0.2 0.09 0.1 0.06 N 21.13 264 166 92.5 17.4 1 8.68 11 7.4 0.3 0.25 0.09 0.1 0.06 N 21.18 423 264 158 30.4 1-17 1 10.5 1 0.3 0.3 0.1 0.15 0.9 N 21.25 660 423 251 43.4 1-26 1 16 1 0.48 0.58 0.1 0.17 0.13 N 41.09 DN40 423 264 158 27.9 1 13.6 17 11 0.48 0.26 0.1 0.16 0.07 N 41.13 660 423 238 43.4 1 22.3 28 1 17.4 1 0.49 0.29 0.15 0.17 0.07 N 41.19 1057 660 396 79.4 1-47 1 28.5 1 0.55 0.35 0.16 0.22 0.1 N 51.10 DN50 1057 660 396 74.4 1 34.7 43.4 27.9 0.62 0.36 0.17 0.22 0.1 N 51.15 1664 1057 634 118 1 55.8 68 1 43.4 1 0.68 0.44 0.19 0.23 0.1 N 51.21 2642 1664 925 192 1-105 1 73 1 0.8 0.61 0.2 0.29 0.15 1 only possible with guided float The operating pressure should be at least double the pressure loss for liquids and five times for gases. The specified pressure losses are valid for water and air at maximum flow rate. Conversion to other products or operating data is performed by KROHNE using the calculation method stipulated in VDI/VDE Directive 3513. 25